Material dispensing systems

ABSTRACT

A method of preparing a composite article including providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel.

CROSS-REFERECE TO RELATED APPLICATION

This patent application is a divisional of U.S. patent application Ser.No 16/031,452, filed Jul. 10, 2018. The disclosure of which is herebyincorporated by reference.

GOVERNMENT RIGHTS

At least some of the subject matter of this application may have beenmade with government support under contract number NWA6000522-0014. Thegovernment may have certain rights in the invention.

BACKGROUND Field of the Invention:

The present disclosure relates, in general, to composite laminates, andin particular, to the manufacture of composite laminates using amaterial dispensing system.

Description of Related Art:

Modern aircraft are manufactured from a wide variety of materials,including steel, aluminum, and a wide variety of composite materials.Most structural components are made from strong, rigid materials.However, in order to conserve weight, the structural components areoften made from a thin layer of metal or composite that includesreinforcement strips of material reinforced with stringers.

Tiltrotor aircraft have complicated proprotor assemblies located atopposing wing tips that operate between a helicopter mode to take off,hover, fly, and land like a conventional helicopter; and an airplanemode. The proprotor assemblies are oriented vertically for a helicoptermode and horizontally for airplane mode. Because the tiltrotor aircraftmust operate in both helicopter mode and airplane mode, and operatewhile transitioning between the two, the wing structure must support theweight of the proprotor assemblies, withstand the forces generated fromthe proprotor assemblies in a variety of modes, and provide a liftingforce sufficient to lift the weight of the aircraft.

FIG. 1 is a partial view of an exemplary prior art tiltrotor wing 10including a torque box structure 30. The torque box structure 30includes skins 20, forward spar 32, and aft spar 34. The skins 20includes stringers 12 extending generally parallel to the longitudinalaxis of the wing 10. The upper skin 20 requires five stringers 12 andthe lower skin 20 requires four stringers 12. The stringers 12 providestiffness and support to the skin 20 and are each an I-beam shapedstiffener as shown in FIG. 2 connected to the interior surface 20a ofthe skin 20. The stiffeners 12 are made from a composite material andextend the depth of the skin 20 assembly into the interior of the wing10 thereby reducing the space available for fuel and other internalsystems.

The skin 20 is constructed of many of layers or “plies” of compositematerials comprised of hundreds of reinforcement strips 28 or “postagestamps” made of various types, sizes, orientations, and thicknesses ofmaterials. The reinforcement strips 28 are made of graduated sizes ofpostage stamp stamps that have been compacted together as shown in FIG.2. The reinforcement strips 28 are located below the stringer 12: (1) toprovide support for the skin 20 against catastrophic buckling; (2) tomaintain shape and contour of the skin 20; (3) to provide stiffness atthe stringer load points; and (4) to distribute pressure into the skin.During manufacture of the skin 20 each reinforcement strips 28 is cut,labeled, and positioned in a mold, which is an extremely time-consumingand laborious process.

Each reinforcement strip 28 is typically cut from a ply ofpre-impregnated material (pre-preg) made of reinforcing fibers such ascarbon, glass, aramid, and the like, that are bonded together with athermoplastic polymer. Pre-preg conventionally has been supplied bymanufacturers as 0° tape (with all its fibers orientated in onedirection in relation to an edge of the pre-preg roll) or 0/90 fabric(continuous fiber in the roll-up direction, 0°, with discontinuous wovenor stitched fibers running transverse to the roll-up direction, 90°having a width between about 75 and 300 mm. Often, to achieve a desiredlaminate characteristic, the plies of pre-preg are layered with theirfibers having different orientations in relation to each other to tailorthe structural properties of the laminates. For example, in applicationsfor forming high strength-low weight complex shaped structures it may bedesired to apply and form one layer of pre-preg at a time on a tool withone or more of the different layers having different fiber orientationsthan another layer. Examples of common layer orientations, besides 0degree and 0/90 degree, include, but are not limited to, 30°, 45°, 60°,90°, 120°, 135°, and 150°. Combinations of these layer orientations arealso needed including, but not limited to, 45°/135°, 60°/150°, 30°/120°.

The cutting and placement of the reinforcement strips 28 in differentorientations is a complex process that is tedious and time consuming.Accordingly, automated tape laying (ATL) or automated fiber placement(AFP) machines have been developed to perform these steps. ATL or AFPmachines use tapes or tows distributed from a moving head that placesand cuts reinforcement strips 28 on a mold or mandrel in an automaticfashion. For instance, ATL machines use one or more tapes each having awidth between about 75 and 300 mm, whereas AFP machines use a number ofsmall width tows that are typically less than about 8 mm wide. Thefibers in tape are usually oriented at either 0° or 90°. The tape or towis fed into a roller head, where heat is applied thereto prior to itsdeposition onto a substrate. The position of the roller head isconstantly moving and repositioned for placement of each ply having adesired orientation on the mold. The roller head may also heat thesubstrate onto which the tape or tow is to be deposited (typically thismay be a layer of tape deposited in a previous step). Under pressurefrom the roller and/or tension, the tape or tow becomes bonded to asubstrate as the thermoplastic polymer within the composite, and withinthe substrate, melts and adheres the tape or tow to the substrate. Thencooling and solidification of the thermoplastic polymer leads toconsolidation of the tape as part of the substrate to which it wasapplied. Typical manufacturing velocities for the rate of laydown oftape are from 0.1 m/min up to 60 m/min, preferably from 1 m/min up to 60m/min. As production velocities increase, there is a risk that thedegree of bonding of the tape or tow to the substrate may decrease andthis can lead to the tape or tow delaminating from the substrate.Moreover, depending upon the size and thickness of a composite articlefor a skin of a tiltrotor wing, complicated robotics repeat complicatedplacement steps of narrow tape or tow that occur over hours. ATL tendsto achieve a much higher deposition rate compared to AFP, but alsoproduces much more waste.

Accordingly, the need has arisen for an improved material dispensingsystem for the manufacture of composite articles for use on a tiltrotoraircraft that addresses one or more of the foregoing issues.

DESCRIPTION OF THE DRAWINGS

The novel features believed characteristic of the embodiments of thepresent disclosure are set forth in the appended claims. However, theembodiments themselves, as well as a preferred mode of use, and furtherobjectives and advantages thereof, will best be understood by referenceto the following detailed description when read in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a cross-sectional view of a prior art tiltrotor wing;

FIG. 2 is a cross-sectional view of a stringer and skin in the prior arttiltrotor wing shown in FIG. 1;

FIG. 3 is a perspective view of a tiltrotor aircraft in helicopter mode,according to one example embodiment;

FIG. 4 is a perspective view of a tiltrotor aircraft in airplane mode,according to one example embodiment;

FIG. 5 is a schematic perspective view of a material dispensing system,according to an exemplary embodiment;

FIG. 6 is a schematic side view of the material dispensing system inFIG. 5;

FIG. 7A is a perspective, section view of a bias ply and non-bias plies,according to an illustrative embodiment;

FIG. 7B is a perspective, section view of bias plies and non-plies,according to an exemplary embodiment;

FIG. 8 is a flow diagram of a method of preparing a composite article,according to an exemplary embodiment;

FIG. 9 is another embodiment of a material dispensing system with aplurality of dispensing heads, according to an illustrative embodiment;

FIG. 10 is an embodiment of a material dispensing system where the frameis a robotic arm; and

FIG. 11 is an embodiment of a material dispensing system where the frameis a gantry, according to an exemplary embodiment.

SUMMARY

In a first aspect, there is a material dispensing system including afirst frame; and a first application head supported by the first frameincluding a first bias ply assembly comprising a bias ply roll supportedon a bias ply dispenser unit, the first bias ply assembly configured topass bias ply material along a bias path; and a first non-bias plyassembly comprising a non-bias ply roll supported by a non-bias plydispenser unit, the non-bias ply assembly configured to pass non-biasply material along a non-bias path; wherein the bias path and thenon-bias path are substantially parallel.

In an embodiment, the first bias ply roll is comprised of a fiber havinga bias orientation.

In an exemplary embodiment, the bias orientation is at least one of thefollowing: about 15°, about 30°, about 45°, about 60°, about 75°, about105°, about 120°, about 135°, about 150°, and about 165.

In an embodiment, the non-bias ply roll is comprised of a fiber having anon-bias orientation.

In another embodiment, the non-bias orientation is at least one of thefollowing: about 0°, about 90°, about 180°, and 270°.

In an illustrative embodiment, at least one of the bias ply roll and thenon-bias ply roll are comprised of a ply having a selected width greaterthan 24 inches.

In an embodiment, the first biased assembly and the first non-biasedassembly are in a stacked horizontal configuration on the firstapplication head.

In another embodiment, at least one of the bias ply roll and thenon-bias ply roll is a ply of resin impregnated fibers.

In an embodiment, the system includes a cutter slidably coupled to thefirst application head and configured to cut at least along a width of abias or non-bias ply.

In yet another embodiment, the system includes an adhesive deliverydevice.

In an embodiment, the first application head moves only in an Xdirection during operation.

In an embodiment, the first frame includes at least one of thefollowing: a pair of movable support members, a gantry, and a roboticarm.

In still another embodiment, the movable support members move along atrack.

In yet another embodiment, the system is programmable.

In a second aspect, there is a material dispensing system including afirst frame; a first application head supported by the first frame, thefirst application head including a non-bias ply assembly, the non-biasply assembly configured to pass non-bias ply material along a non-biaspath; a second frame; and a second application head supported by thesecond frame, the second application head including a bias ply assembly,the bias ply assembly configured to pass bias ply material along a biaspath; wherein the first frame and the second frame move in an Xdirection during operation.

In an embodiment, the bias path and the non-bias path are substantiallyparallel.

In a third aspect, there is a method of preparing a composite articleincluding: providing a first bias assembly with a first bias roll;providing a first non-bias assembly with a first non-bias roll;positioning the first bias assembly to a dispensing position; dispensinga bias ply from the first bias roll along a bias path on a mold; cuttingthe bias ply; positioning the first non-bias assembly to a dispensingposition; dispensing a non-bias ply from the first non-bias roll; andcutting the non-bias ply; wherein the bias path and the non-bias pathare substantially parallel.

In an embodiment, the first bias assembly and the first non-biasassembly are disposed on a frame.

In an illustrative embodiment, the first bias assembly is disposed on afirst frame and the first non-bias assembly is disposed on a secondframe.

In an exemplary embodiment, the method includes a step of cutting areinforcement strip from at least one of the bias ply and the non-biasply.

Other aspects, features, and advantages will become apparent from thefollowing detailed description when taken in conjunction with theaccompanying drawings, which are a part of this disclosure and whichillustrate, by way of example, principles of the inventions disclosed.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Illustrative embodiments of material dispensing systems and methodstherefor are described below. In the interest of clarity, all featuresof an actual implementation may not be described in this specification.It will of course be appreciated that in the development of any suchactual embodiment, numerous implementation-specific decisions must bemade to achieve the developer's specific goals, such as compliance withsystem-related and business-related constraints, which will vary fromone implementation to another. Moreover, it will be appreciated thatsuch a development effort might be complex and time-consuming but wouldnevertheless be a routine undertaking for those of ordinary skill in theart having the benefit of this disclosure.

In the specification, reference may be made to the spatial relationshipsbetween various components and to the spatial orientation of variousaspects of components as the devices are depicted in the attacheddrawings. However, as will be recognized by those skilled in the artafter a complete reading of the present application, the devices,members, apparatuses, etc. described herein may be positioned in anydesired orientation. Thus, the use of terms such as “above,” “below,”“upper,” “lower,” or other like terms to describe a spatial relationshipbetween various components or to describe the spatial orientation ofaspects of such components should be understood to describe a relativerelationship between the components or a spatial orientation of aspectsof such components, respectively, as the device described herein may beoriented in any desired direction.

Referring to FIGS. 3 and 4, a tiltrotor aircraft 101 is illustrated.Tiltrotor aircraft 101 can include a fuselage 103, a landing gear 105, atail member 107, a wing 109, a propulsion system 111, and a propulsionsystem 113. Each propulsion system 111, 113 includes a fixed engine anda rotatable proprotor 115, 117, respectively. Each rotatable proprotor115, 117 have a plurality of rotor blades 119, 121, respectively,associated therewith. The position of proprotors 115, 117, as well asthe pitch of rotor blades 119, 121, can be selectively controlled inorder to selectively control direction, thrust, and lift of tiltrotoraircraft 101.

FIG. 3 illustrates tiltrotor aircraft 101 in helicopter mode, in whichproprotors 115 and 117 are positioned substantially vertical to providea lifting thrust. FIG. 4 illustrates tiltrotor aircraft 101 in anairplane mode, in which proprotors 115, 117 are positioned substantiallyhorizontal to provide a forward thrust in which a lifting force issupplied by wing 109. It should be appreciated that tiltrotor aircraftcan be operated such that proprotors 115, 117 are selectively positionedbetween airplane mode and helicopter mode, which can be referred to as aconversion mode.

The proprotors 115 and 117 rotate from a conversion axis C located abovean upper wing skin 123. An advantage of locating the conversion axis Cof the proprotors 115 and 117 above the upper wing skin 123 is that thefore/aft location of the proprotors 115 and 117 can be moved to shiftthe center of gravity of the aircraft in the various flight modes asdescribed by U.S. Pat. No. 9,174,731, issued Nov. 3, 2015, which ishereby incorporated by reference in its entirety. As such, locating theconversion axis of the proprotors 115 and 117 above the upper wing skin123 allows the fore/aft location of the proprotors 115 and 117 to beoptimized for the center of lift in a particular flight mode.

The aircraft 101 has a maximum range further than a conventionaltiltrotor aircraft (wing shown in FIGS. 1 and 2) achieved at least inpart by the wing structure including the wing skin 123. The wingstructure 109 provides structural support for the propulsion systems111, 113 and fuselage 103 and lifting force sufficient to lift theweight of the aircraft 101. The wing structure 109 is configured todistribute loads and the shearing motion generated by the propulsionsystems 111, 113 during the various flight modes. The improvedstructural support of the wing member 109 also provides fuel bays havingno I-beam projections on the fuel supporting surfaces, which providesmore space in the fuel bay for fuel capacity.

This disclosure depicts and describes material dispensing systems andmethods relating thereto that can be used to manufacture the wing skin123 and other composite articles for the tiltrotor wing structure 109.The material dispensing systems, components and features thereof, andmethods relating thereto depicted and/or described herein can be usedwith any aircraft having one or more composite articles, includingtiltrotor aircrafts, helicopters, tilt wing aircrafts, unmanned aerialvehicles (UAVs), hovercrafts, and other vertical lift or VTOL aircrafts,or can further be used with any device having a composite component,including devices with propellers, windmills, and turbines. Further, anyfeatures of one embodiment of the material dispensing systems andmethods relating thereto in this disclosure can be used with any otherembodiment of the material dispensing systems and methods in thisdisclosure such that the other embodiment has the same or similarfeatures, operates in the same or similar way, or achieves the same orsimilar functions. Some components of this disclosure are depicted bygraphic shapes and symbols. Unless this disclosure specifies otherwise,such components should be understood to include the same or similarcharacteristics and features as those components that are named ordescribed, though the graphic shapes and symbols may not depict eachsuch characteristic or feature.

In an embodiment, as shown in FIGS. 5-6, a material dispensing system200 includes a first frame 220, a first application head 230 supportedby the first frame 220, and a mold 224. The first application head 230is configured to dispense, cut, and apply plies from a first bias plyassembly 240 and a first non-bias ply assembly 250 onto the mold 224.The mold 224 is disposed on a machine base 226.

In an embodiment, the first frame 220 includes movable support members222 disposed in a pair of tracks 225. In the illustrative embodiment,the tracks 225 are mounted in the floor; however, in other embodiments,the tracks 225 are mounted to or in a ceiling or a wall. In someillustrative embodiments, the first frame 220 includes a drive system227 that permits the movable support members 222 to traverse across thetracks 225 during operation. In an embodiment, the drive system 227includes wheels 228 operably connected to the movable support members222 and received in a groove in the tracks 225. In an embodiment, thedrive system 227 includes an electric motor 229 for driving wheels 228on tracks 225. In other embodiments, drive system 227 can includesprockets, chains, and/or axles to move support members 222.

In an embodiment, the first frame 220 and the first application head 230are designed to move in only in an X motion direction as depicted inFIG. 5. The X motion is motion along a longitudinal axis X. The Y motionis motion along the transverse axis Y that is perpendicular tolongitudinal axis X. The Z motion is motion along a vertical axis Z. Insome embodiments, the first application head 230 is designed to move ina Z motion. Advantageously the first frame 220 and the first applicationhead 230 cannot and do not move in a Y motion, which eliminates roboticplacement systems used in ATL and AFT machines. Accordingly, thematerial dispensing system 200 reduces operating costs, manufacturingtime, and maintenance as compared to conventional placement systems(e.g., ATL and AFT machines).

In an illustrative embodiment, the first application head 230 isdisposed generally at the top and front of the first frame 220. Thefirst application head 230 includes one or more first bias plyassemblies 240 (e.g., a second, third, fourth, or fifth bias plyassemblies). The number and size (width) of the bias ply assemblies candepend on the type of the bias material and desired orientation of thebias ply material desired for the composite. The first application head230 can include one or more first non-bias ply assemblies (e.g., asecond, third, fourth, or fifth bias ply assemblies). The number andsize (width) of the non-bias ply assemblies can depend on the type ofnon-bias material and desired orientation of the non-bias ply materialdesired for the composite.

In the illustrative embodiment, the first application head 230 includesthe first biased assembly 240, the first non-biased assembly 250, and,optionally, a second non-biased assembly 270 in a stacked horizontalconfiguration such that the longitudinal axis of each assembly 240, 250,270 is substantially perpendicular to the tracks 225 during operation.In other embodiments, the first application head 230 can comprise aplatform on the first frame 220 with mounting brackets for supportingthe first biased assembly 240 and the first non-biased assembly 250.

The first bias ply assembly 240 includes first a bias ply roll 242supported on a bias ply dispenser unit 244. The bias ply roll 242 iscomprised of one ply of a tape or fabric having a selected width that iscomposed of fibers having a bias orientation. The fabric of the bias plyroll 242 can be comprised of a bidirectional weave (for example, but notlimitation, 45° and 135°) in a biased orientation. The bidirectionalweave can include at least one of the following, but is not limited to,a plain weave, 8 harness satin weave, 4 shaft satin weave, 8 shaft satinweave, crowfoot satin weave, 5 harness satin weave, and 8 shaft satinweave. The tape of the bias ply roll 242 can be comprised ofunidirectional fibers (not woven) in a biased orientation. In anexemplary embodiment, the selected width is at least one of thefollowing: greater than 24 inches, greater than 48 inches, greater than50 inches, greater than 60 inches, greater than 64 inches. The selectedwidth of the bias ply roll 242 is greater than ATL or AFP machines so asto substantially increase the manufacturing and reduce the complexity ofthe system 200 as compared to conventional ATL or AFP machines. Thefibers in the bias ply roll 242 can be continuous filaments or fibersincluding one or more of glass, carbon, graphite, basalt, an aromaticpolyamide (i.e. “aramid”) material, a variant of an aromatic polyamidematerial (e.g., a polyparaphenylene terephthalamide material, such asKevlar® by E.I. du Pont de Nemours and Company of Richmond, Va.), or thelike.

In addition, the fibers of the bias ply roll 242 have a biasorientation. Bias orientation means a fiber having an oblique anglerelative to center axis 201 a (e.g., an oblique angle is neitherparallel nor at right angles to center axis 201 a). For example, thebias orientation is a fiber having an angle not oriented at either 0°,90°, 180°, or 270° relative to a center axis 201 a of the compositearticle. In an embodiment, the bias orientation of the fiber has angleof in varying orientations about 15°, about 30°, about 45°, about 60°,about 75°, about 105°, about 120°, about 135°, about 150°, and/or about165° relative to the center axis 201 a of the composite article;however, it should be appreciated that the bias orientation of a fibercan be any angle having an oblique orientation (e.g., any angle morethan 0° and less than 90°, greater than 90° and less than 180°, greaterthan 180° and less than 270°, and greater than 270° and less than) 360°.In the illustrative embodiment shown in FIG. 5, the first bias ply roll242 is a ply with a bias weave fabric having a bias orientation of about45° and 135°. In another exemplary embodiment, a ply 212 ofunidirectional tape having a bias orientation of about 45° in FIG. 7A.In another illustrative embodiment shown in FIG. 7B, plies 212, 215 ofunidirectional tape have a bias orientation of about 45° and plies 213,214 of unidirectional tape have a bias orientation of about 135°.

The bias ply dispenser unit 244 can be a conventional fabric dispensingdrive. In an embodiment, the bias ply dispenser unit 244 is a variablespeed drive to dispense the bias ply from the bias ply roll 242 onto themold 224.

The first bias ply assembly 240 is configured to pass bias ply materialalong a bias path 246. The bias path 246 is parallel to the tracks 225.In the illustrative embodiment, the bias path 246 is parallel to thelongitudinal and center axis 201 of the composite article 201. It willbe appreciated that one of the novel features of the material dispensingsystems and methods herein is the use of a bias ply roll 242 with fibershaving a bias orientation. Advantageously the fibers in the biasorientation in the bias ply roll 242 permit the mere dispensing of theply from the first bias ply assembly along the bias path 246. Theorientation of the first bias ply roll 242 and assembly 240 remainsperpendicular to the longitudinal and center axis 201 of the compositearticle 201 during operation of the system 200, thereby increasingdispensing velocities and eliminating complex and expensive dispensingheads used by ATL and AFP machines.

The first non-bias ply assembly 250 includes first a non-bias ply roll252 supported on a non-bias ply dispenser unit 254. The non-bias plyroll 252 is comprised of one ply of a tape or fabric having a selectedwidth that is composed of fibers having a non-bias orientation. Thefabric of the non-bias ply roll 252 can be comprised of a bidirectionalweave (for example, but not limitation, 0° and 90°) in a non-biasedorientation. The bidirectional weave can include at least one of thefollowing: a plain weave, 8 harness satin weave, 4 shaft satin weave, 8shaft satin weave, crowfoot satin weave, 5 harness satin weave, and 8shaft satin weave. The tape of the non-bias ply roll 252 includes, butis not limited to, unidirectional fibers (not woven) in a non-biasedorientation (for example, but not limitation, fibers at 0° or 90°relative to the center axis 201 a). Tape of the non-bias ply roll iscommonly referred to as Uni. In an exemplary embodiment, the selectedwidth is at least one of the following: greater than 24 inches, greaterthan 48 inches, greater than 50 inches, greater than 60 inches, greaterthan 64 inches. The selected width of the non-bias ply roll 252 isgreater than ATL or AFP machines so as to substantially increase themanufacturing and reduce the complexity of the system 200 as compared toconventional ATL or AFP machines. The fibers in the non-bias ply roll252 can be continuous filaments or fibers including one or more ofglass, carbon, graphite, basalt, an aromatic polyamide (i.e. “aramid”)material, a variant of an aromatic polyamide material (e.g., apolyparaphenylene terephthalamide material, such as Kevlar® by E.I. duPont de Nemours and Company of Richmond, Va.), or the like.

In addition, the fibers of the non-bias ply roll 252 have a non-biasorientation. A non-bias orientation is a fiber having an angle that isparallel or at right angles to center axis 201 a (e.g., the fiber isoriented at about 0°, about 90°, about 180°, or about 270° relative tocenter axis 201 a of the composite article). In the illustrativeembodiment shown in FIG. 5, the first non-bias ply roll 252 includes,but is not limited to, unidirectional tape having a non-bias orientationof about 0°. In another exemplary embodiment shown in FIG. 7A, a ply 210of unidirectional tape has a non-bias orientation of about 0° and a ply211 of plain weave fabric has fibers in non-bias orientations of about0° and 90°. In another illustrative embodiment shown in FIG. 7B, plies210, 217 of unidirectional tape have a non-bias orientation of about 0°and plies 211, 216 of unidirectional tape have a non-bias orientation ofabout 90°.

The non-bias ply dispenser unit 254 can be a conventional fabricdispensing drive. In an embodiment, the non-bias ply dispenser unit 254is a variable speed drive to dispense the non-bias ply from the non-biasply roll 252 onto the mold 224.

The first non-bias ply assembly 250 is configured to pass a non-bias plymaterial along a non-bias path 256. The non-bias path 256 is parallel tothe tracks 225. In the illustrative embodiment, the non-bias path 256 isparallel to the longitudinal and center axis 201 of the compositearticle 201. The orientation of the first non-bias ply roll 252 andassembly 250 remains perpendicular to the longitudinal and center axis201 of the composite article 201 during operation of the system 200. Inan embodiment, bias path 246 and the non-bias path 256 are substantiallyparallel and, in the illustrative embodiment, the bias and non-biaspaths 246, 256 are substantially identical, which can improve dispensingvelocities and eliminating complex and expensive dispensing heads usedby ATL and AFP machines.

In some embodiments, as shown in FIG. 5, the first application head 230includes a second non-bias ply assembly 270 comprising a second non-biasply roll 272 supported by a second non-bias ply dispenser unit 274. Thesecond non-bias ply assembly 270 is configured to pass non-bias plymaterial along a second non-bias path 276. In an embodiment, bias path246 and the first and second non-bias paths 256, 276 are substantiallyparallel and, in the illustrative embodiment, the bias and first andsecond non-bias paths 246, 256, 276 are substantially identical. In theillustrative embodiment shown in FIG. 5, the second non-bias ply roll272 is a plain-weave fabric having a non-bias orientation of about 0°and about 90°.

During operation, as illustrated in FIGS. 5-6, the first applicationhead 230 is positioned on the track 225 for dispensing a selected plyfrom the ply roll (e.g., rolls 242, 252, or 272) for a desired plylayout. In an exemplary embodiment shown in FIG. 6, each ply roll isassociated with a tension member 238 to impart tension on the ply as itis being placed on the mold 224. The tension member 238 is supported bythe first application head 230. In an embodiment, an end of the ply canbe secured to the mold 224 by a conventional means such as a materialclamp or weight 223. In an embodiment, as the first frame 220 moves onthe tracks 225 to the selected position for the desired ply location onthe mold 224, the ply is dispensed from the respective roll 242, 252,272. In some embodiments, sensors on the mold 224 can be incommunication with a control computer 286 that controls and drives thebias and non-bias dispenser units 244, 254, 274 to dispense a ply ontothe mold 224.

In an illustrative embodiment, as shown in FIGS. 5-6, the firstapplication head 230 includes a cutter 280. The cutter 280 is slidablycoupled to the front surface of the first application head 230 and isconfigured to cut at least along the width of the plies being dispensedtherefrom. In an embodiment, the cutter 280 slides across the width ofthe plies as well as vertically along a track 282. In some embodiments,the cutter can be movable and configured to perform the step of cuttinga ply from at least one roll 242, 252, 272 and, optional, the step ofcutting a ply reinforcement strip from a ply on at least one roll 242,252, 272. In some embodiments, the step of cutting occurs as the ply isdispensed from the respective roll 242, 252, 272. In some embodiments,the cutter 280 performs the step of cutting when the ply is dispensedand at least partially on the mold 224. In some embodiments, the cutter280 is a laser cutter and/or other suitable device. In some embodiments,the cutter 280 can perform the step of trimming. In an embodiment, thecutter 280 is in communication with the control computer 286 toselectively adjust the cutting and trimming of the ply.

Once the ply and/or reinforcement strip has been dispensed, cut, andpositioned onto the mold 224, the first application head 230 isrepositioned and the process starts again until the layers of thecomposite article 201 are complete.

In an embodiment, the material dispensing system 200 includes a controlcomputer 286 communicably connected to at least one controllablecomponents (e.g., the dispenser units 244, 254, 274; the drive system227; the cutter 280). In an embodiment, the control computer 286 isconnected via wires 288 or through a wireless network 204. The controlcomputer 286 can be programmable to optimize ply dispensing, placement,and cutting as described herein with regard to the control computer 286.The control computer 286 includes memory 286 a and a processor 286 b.The memory 286 a stores ply layout parameters 287 for composite articlesincluding the bias orientation, non-bias orientation, weave, type of ply(e.g., tape or fabric) etc. The processor 286 b includes a programmingmodule 289 a for generating dispensing, placement, and cutting programsand a validation module 289 b for validating the results. At a highlevel, the programming module 289 a receives a selection of a componentand ply layout parameters and selects a configuration for the firstapplication head 230 and operating parameters 285 for the dispensing,placement, and cutting steps. The programming module 289 a evaluatessequences of motions based on the ply layout geometry identified in theply layout parameters 287 and selects a sequence of motions based on,for example, but not limitation, the compressive strength of thecomposite article 201. Once selected, the programming module 289 aautomatically generates a dispensing, placement, and cutting program 291based on the selected sequence of motions and the operating parameters285. The programming module 289 a can transmit the dispensing,placement, and cutting program 291 to the material dispensing system 200through the network 204. In an embodiment, the dispensing, placement,and cutting program 291 is reviewed by a validation module 289 b. Thevalidation module 289 b evaluates a model of a composite articlegenerated from the dispensing, placement, and cutting program 291 toensure the composite article will meet operating specifications.

As for a more detailed description of the illustrated implementation,the control computer 286 includes memory 286 a and the processor 286 band comprises an electronic computing device operable to receive,transmit, process and store data associated with system 200. Forexample, the control computer 286 may be any computer or processingdevice such as a mainframe, a blade server, general-purpose personalcomputer (PC), Macintosh, workstation, Unix-based computer, or any othersuitable device. Generally, FIG. 5 provides merely one example of acomputer that may be used with the disclosure. In other words, thepresent disclosure contemplates computers other than general purposecomputers as well as computers without conventional operating systems.As used in this document, the term “computer” is intended to encompass apersonal computer, workstation, network computer, or any other suitableprocessing device. For example, although FIG. 5 illustrates one controlcomputer 286 that may be used with the disclosure, system 200 can beimplemented using a pool of computers.

Memory 286 a may include any memory or database module and may take theform of volatile or non-volatile memory including magnetic media,optical media, Random Access Memory (RAM), Read Only Memory (ROM),removable media, or any other suitable local or remote memory component.In the illustrated implementation, memory 286 a includes operatingparameters 285, ply layout parameters 287, and dispensing, placement,and cutting program 291. Ply layout parameters 287 include one or moreentries or data structures that identify ply geometry, bias orientation,non-bias orientation, and associated features.

Operating parameters 285 include any parameters, variables, algorithms,instructions, rules, objects or other directives for operating aparticular material dispensing system 200 to perform dispensing,placement, and cutting of plies from rolls 242, 252, 272 for a compositearticle 201.

The dispensing, placement, and cutting program 291 is any application,program, module, process, or other software that may generate commandsto execute dispensing, placement, and cutting of plies from rolls 242,252, 272 using the material dispensing system 200. For example, thedispensing, placement, and cutting program 291 may generate commands tocontrol the position of the first frame 220 (via drive system 227)through a sequence of motions or paths and stopping at predefined pointsfor dispensing, placement, and cutting of a ply at specific locations onthe mold 224.

The control computer 286 also includes the processor 286 b. Processor286 b executes instructions and manipulates data to perform theoperations of the control computer 286 such as, for example, a centralprocessing unit (CPU). Although FIG. 5 illustrates a single processor286 b in the control computer 286, multiple processors 286 b may be usedaccording to particular needs and reference to the processor 286 b ismeant to include multiple processors 286 b where applicable. Asillustrated, the processor 286 b includes the programming module 289 aand the validation module 289 b.

The programming module 289 a can include any software, hardware,firmware, or combination thereof to automatically generate operatingparameters 285. For example, the programming module 289 a may receive aselection of a composite article and generate operating parameters 285based on a model for the selected composite article.

The validation module 289 b can include any software, hardware,firmware, or combination thereof configured to evaluate a compositearticle generated from the dispensing, placement, and cutting program291 to ensure the generated composite article will meet operatingspecifications.

Network 204 facilitates wireless or wireline communication between thecontrol computer 286 and the material dispensing system 200. Network 204may communicate, for example, Internet Protocol (IP) packets, FrameRelay frames, Asynchronous Transfer Mode (ATM) cells, voice, video,data, and other suitable information between network addresses. Network204 may include one or more local area networks (LANs), radio accessnetworks (RANs), metropolitan area networks (MANs), wide area networks(WANs), all or a portion of the global computer network known as theInternet, and/or any other communication system or systems at one ormore locations. As appropriate, the control computer 286 generatesrequests and/or responses and communicates them to another client, user,server, or other computer systems located in or beyond network 204.

In some embodiments, the material dispensing system 200 is notprogrammable.

The configuration of the rolls 242, 252, 272 can be selectively adjustedfor the desired ply layout (e.g., the desired order and orientation ofthe ply) for the particular composite article 201 being formed. FIG. 7Aillustrates an exemplary ply layout for plies dispensed and cut fromrolls 242, 252, 272. Ply 210 is an exemplary embodiment of a ply ofunidirectional tape having a non-bias orientation of about 0° dispensedfrom the first non-bias ply roll 252. Ply 211 is an exemplary embodimentof a ply of plain weave fabric having a non-bias orientation of about 0°and about 90° dispensed from the second non-bias ply roll 272. Ply 212is an exemplary embodiment of a ply of bias weave fabric having a biasorientation of about 45° and about 135°.

Another illustrative embodiment of a desired ply layout for a compositearticle 201 is shown in FIG. 7B. The layout in FIG. 7B includes twoplies of unidirectional fabric 210, 217 having a non-bias orientation ofabout 0° dispensed from the first non-bias ply roll 252. Two plies of aunidirectional fabric 211, 216 having a non-bias orientation of about90° would be dispensed from a third non-bias ply roll (not shown)disposed on the first application head 230. Two plies of biasunidirectional fabric 212, 215 having a bias orientation of about 45°would be dispensed from a second bias ply roll (not shown) disposed onthe first application head 230. Two plies of bias unidirectional tape213, 214 having a bias orientation of about 135° would be dispensed froma third bias ply roll (not shown) disposed on the first application. Inthis illustrative embodiment, the first application head 230 includesfour rolls having different ply orientations/weaves and includes atleast one bias ply roll 242; however, it should be appreciated thatother embodiments may have fewer or more rolls but include at least onebias ply roll 242.

In an embodiment, the material dispensing system 200 dispenses and cutstape and/or fabric that are dry fibers that can be wetted with apolymeric matrix either by hand or by injecting the polymeric matrixinto a closed mold via an adhesive deliver device 290, as schematicallyshown in FIG. 5. In an embodiment, the polymeric matrix can be a film,paste, or liquid. In an embodiment, the polymeric matrix can be anysuitable resin system, such as a thermoplastic or thermosetting resin.Other exemplary resins can include epoxy, polyimide, polyamide,bismaleimide, polyester, vinyl ester, phenolic, polyetheretherketone(PEEK), polyetherketone (PEK), polyphenylene sulfide (PPS), and thelike.

In another embodiment, the fibers are impregnated or otherwise situatedin a polymeric matrix as a ply of pre-preg on one or more of the rolls242, 252, and/or 272. In an embodiment, the pre-preg ply can be anintermediate modulus epoxy resin impregnated carbon fiber fabric on aroll. The intermediate modulus epoxy impregnated carbon fiber fabric canbe stiffer than conventional composite fabrics which allows for fewerplies, which reduces the weight and manufacturing cost, while the epoxyresin system can provide tolerance to damage. In an embodiment, apre-preg ply is dispensed from a roll (e.g., roll 242, 252, 272) and cutvia cutter 280. The step of dispensing can include smoothing the pliesto remove any pockets of air using compaction member. In some exemplaryembodiment, the compaction member comprises a compaction roller thatmoves independently from the first application head 230.

Once the fibers are in a polymeric matrix, heat and/or pressure can beused to cure the plies in the polymeric matrix. Once cured, thecomponent may then be machined to its final shape.

FIG. 8 is a flowchart illustrating an example method 300 for preparing acomposite article using the material dispensing system 200. Method 300is described with respect to system 200 of FIG. 5. Though, systems 400,500, and 600 contemplate using or implementing any suitable techniquefor performing these and other tasks. Method 300 is for illustrationpurposes only and that the described or similar techniques may beperformed at any appropriate time, including concurrently, individually,or in combination. In addition, many of the steps in this flowchart maytake place simultaneously and/or in different orders than as shown.Moreover, systems 200, 400, 500, and 600 may use methods with additionalsteps, fewer steps, and/or different steps, so long as the methodsremain appropriate.

Method 300 includes the following steps: a step 302 of providing a firstbias assembly with a first bias roll, a step 304 of providing a firstnon-bias assembly with a first non-bias roll, a step 306 of positioningthe first bias assembly to a dispensing position, a step 308 ofdispensing a bias ply from the first bias roll along a bias path on amold, a step 310 of cutting the bias ply, an optional step 312 ofcutting a ply reinforcement strip, a step 316 of positioning the firstnon-bias assembly to a dispensing position, a step 318 of dispensing anon-bias ply from the first non-bias roll along a non-bias path on amold, a step 320 of cutting the non-bias ply, and an optional step 322of cutting a ply reinforcement strip. The bias path and the non-biaspath are parallel. In some embodiments, the bias path and non-bias pathare substantially identical.

In some embodiments, the method 300 includes a step of trimming a plylayup on the mold.

FIG. 9 is another example of a material dispensing system 400. Certaincomponents of the material dispensing system 400 are as described abovein connection with the material dispensing system 200. Those componentsbear similar reference characters thereto, but with a leading ‘4’ ratherthan a leading ‘2’. The material dispensing system 400 includes a firstframe 420, a second frame 421, and a third frame 424 (e.g., a pluralityof frames). The first frame 420 includes a first application head 430;the second frame 421 includes a second application head 431, and thethird frame 424 includes a third application head 434. Each of thefirst, second, and third frames 420, 421, 424 can move along tracks 425.Tracks 425 include an additional storage tracks 425a, 425b to permit thefirst and second frames to be stored therein when not in operation. Thefirst, second, and third frames 420, 421, 424 can be operatively coupledto a drive system 427 such that the first, second, and third frames moveonly in an X direction during dispensing, placement, and cuttingprocesses. The first, second, and third frames 420, 421, 424 can bedriven independently by the drive system 427 (e.g., only the first frame420, the second frame 421, or the third frame 424 at one time). In otherembodiments, more than one first, second, and third frames 420, 421, 424move along tracks 225 during operation. The material dispensing system400 can include a network 404 and control computer 486 as describedabove with respect to system 200 although not shown in FIG. 9.

The first, second, and third application heads 430, 431, 434 eachinclude only one biased assembly 440 or non-biased assembly 450, 470. Inthe illustrative embodiment, the first application head 430 includes afirst non-biased assembly 450; the second application head 431 includesa biased assembly 440, and the third application head 434 includes asecond non-biased assembly 470. In an embodiment, the system 400 with aplurality of frames (e.g., frames 420, 421, 424) includes at least onebiased assembly 440.

The configuration of the first, second, and third frames 420, 421, 424and the respective first, second, and third heads 430, 431, 434 can beselectively adjusted for the desired ply layout. For example, more orless frames can be included in system 400 to add additional biasedand/or non-biased assemblies. In an embodiment, the system 400 with aplurality of frames are configured such that each frame includes onlyone biased or non-biased assembly.

FIG. 10 is another example of a material dispensing system 500. Certaincomponents of the material dispensing system 500 are as described abovein connection with the material dispensing system 200. Those componentsbear similar reference characters thereto, but with a leading ‘5’ ratherthan a leading ‘2’. FIG. 10 illustrates an example of the first frame220 comprising a robotic arm 520. The robotic arm 520 may navigate orotherwise move through a manufacturing factory and position itselfadjacent to mold 224 and execute the dispensing, placement, and cuttingprocess described herein. In an embodiment, the robotic arm 520 movesalong a pair of tracks as shown in FIG. 5 to perform the dispensing,placement, and cutting process. The material dispensing system 500includes a network 504 and control computer 586 as described above withrespect to system 200 although not shown in FIG. 10.

In an embodiment, the robotic arm 520 includes, a support member 522, amobile platform 523, a monitoring system 524, and a first applicationhead 530. The first application head 530 is mounted on the supportmember 522, and the support member 522 is mounted on the mobile platform523. The mobile platform 523 is configured to navigate through amanufacturing facility to a position proximate mold 224, and the supportmember 522 is configured to move the first application head 530 topredefined position at least proximate and above the mold 224. Duringoperation, the support member is configured to move during thedispensing, placement, and cutting processes such that the bias path andnon-bias paths 246, 256 are parallel. In some embodiments, the bias pathand the non-bias paths 246, 256 are substantially identical.

The robotic arm 520 can include any software, hardware, firmware, or acombination thereof configured to move in multiple axes or degrees offreedom. As illustrated, the support member 522 includes links connectedby joints that enable rotational motion or translational displacement.In the illustrated implementation, the support member 522 enables motionin 6 axes such as X, Y, Z, pitch, yaw, and roll. Using these multipleaxes, the robotic arm 520 can be configured to move the firstapplication head 230 to multiple predefined positions at least proximateand above the mold 224.

The mobile platform 523 can include any software, hardware, firmware, ora combination thereof configured to navigate or otherwise move through afacility (e.g., manufacturing facility). The mobile platform 523 maydetermine locations using positing data such as radio frequencyidentifier (RFID) signals, global positioning system (GPS), indoor GPS,photogrammetry, laser tracking, optical CMM, or others. In someinstances, the mobile platform 523 is an omni-directional platformallowing for motion in any direction. In some implementations, themobile platform 523 includes a positioning and safety monitoring system524 configured to monitor the environment. In some examples, thepositioning and safety monitoring system 524 may be configured to scan(e.g., continuously scan) the working envelope to monitor for humanmovement or obstructions. In some examples, the positioning and safetymonitoring system 524 may be configured to provide position feedback tothe control computer 286.

FIG. 11 is another example of a material dispensing system 600. Certaincomponents of the material dispensing system 200 are as described abovein connection with the material dispensing system 200. Those componentsbear similar reference characters thereto, but with a leading ‘6’ ratherthan a leading ‘2’. FIG. 11 illustrates an example of the first frame220 comprising a gantry 620. The gantry 620 includes a pair of rails 625supported by stationary support members 622. The pair of rails 625support a first application head 630 configured to move in at least an Xmotion direction. In the embodiment shown, the gantry 620 is stationaryand the first application head 630 moves to a position for dispensingplies from at least one first biased assembly 640 onto the mold 626. Insome embodiments, the first application head 630 is configured to moveonly in an X motion direction. In other embodiments, the firstapplication head 630 is configured to move in X, Y, and Z motions. Thematerial dispensing system 600 includes a network 604 and controlcomputer 686 as described above with respect to system 200 although notshown in FIG. 11.

In an embodiment, a mold 624 is disposed on a machine base 626. In theillustrative embodiment, the machine base 626 is disposed between thestationary support members 622. In other embodiments, the machine base626 is disposed along the transverse axis Y (e.g., generallyperpendicular to the pairs of rails 625, which are aligned with thelongitudinal axis X).

In the illustrative embodiment, the first application head 630 includesthe first biased assembly 640, the first non-biased assembly 650, and,optionally, a second non-biased assembly 670 each being supported by anarm 635. The arm 635 supports the respective assembly 640, 650, 670 andprovides power thereto to operate the dispenser unit 644, 654, 674 (notshown). Each assembly 640, 650, 670 includes the respective ply roll642, 652, 672 as described with respect to material dispensing system200. In some embodiments, each assembly 640, 650, 670 can include arespective tension member 638 mounted and powered by the respective arm635. In still some illustrative embodiments, each assembly 640, 650, 670includes a respective take-up roll 639 supported and powered by a secondarm 637. The second arm 637 is disposed on the first application head630 and can move therewith.

In an illustrative embodiment, the material dispensing system 600includes at least one ply roll 642, 652, 672 comprised of one ply ofpre-preg 648 and a backing paper 647 adhered thereto. Since the fibersin the pre-preg ply 648 are impregnated in a polymeric matrix and canhave a sticky texture, a backing paper 647 is in contact with the ply ofpre-preg 648 while on the ply roll 642. The backing paper 647 needs tobe removed from the pre-preg ply 648 prior to placement on the mold 624.Accordingly, a separator member 636 is supported by the respective arm635 to separate the backing paper 647 from the pre-preg ply 648 as theply 648 is dispensed onto the mold 624. As the backing paper 647 isseparated from the pre-preg ply 648, the backing paper 647 is rotatedaround the respective tension member 638 and up to the take-up roll 639and wound therearound.

System 600 includes a second movable head 632 that moves in X, Y, Zmotions and independently from the first application head 630. Thesecond movable 632 includes a support arm 633a to support componentsthereon.

System 600 includes a cutter 680 mounted to the support arm 633a on thesecond movable head 632. In an embodiment, the cutter 680 is a lasercutter mounted on a track 682 supported by a movable arm 684. Themovable arm 684 can be configured to move in X, Y, Z motions for cuttingthe length and width during or after placement of ply 648.

System 600 also includes a compaction member 633 for pushing the prepregply 648 down onto the mold 624. In an embodiment, the compaction member633 is a compacting roller disposed on the support arm 633a. The step ofdispensing can include smoothing a ply or several plies to remove anypockets of air using the compaction member 633. In some exemplaryembodiment, the compaction member 633 moves independently from the firstapplication head 230. In some other embodiments, the compaction member633 may be disposed on or otherwise associated with the firstapplication head 630.

The material dispensing systems and methods described herein canadvantageously provide at least one of the following benefits: pliesthat cover a larger acreage of a near constant cross-section, as opposedto placing a constantly varying amount of material and sizes of materialdown around highly tailored features as shown in the prior art FIG. 2; agreatly reduced total ply count and part count as compared to the priorart in FIG. 2; the resulting composite article has sufficient stiffnessand torsional support for large area aircraft composites (e.g., wingskin 123, spar ribs); low cost composite tooling as compared to thetooling required for the pieces and ply buildups used in theconventional tiltrotor wing shown in FIGS. 1-2; a combination of themethods described herein can reduce overall labor costs by more than 50%as compared to the current labor costs for the conventional tiltrotorwing shown in FIGS. 1-2; allows for point-of-use manufacturing for thecomposite articles; reduces the number of quality defects as compared tothe quality defects in the conventional tiltrotor wing in FIGS. 1 and 2;simple de-tooling; reduces costs; reduces cycle time; and increasesmaterial throughput.

The terms “a” and “an” are defined as one or more unless this disclosureexplicitly requires otherwise.

The term “substantially” is defined as largely, but not necessarilywholly, what is specified (and includes what is specified; e.g.,substantially 90 degrees includes 90 degrees), as understood by a personof ordinary skill in the art. In any disclosed embodiment, the terms“substantially,” “approximately,” and “about” may be substituted with“within [a percentage] of” what is specified, where the percentageincludes 0.1, 1, 2, and 5 percent.

Terms such as “first” and “second” are used only to differentiatefeatures and not to limit the different features to a particular orderor to a particular quantity.

At least one embodiment is disclosed and variations, combinations,and/or modifications of the embodiment(s) and/or features of theembodiment(s) made by a person having ordinary skill in the art iswithin the scope of the disclosure. Alternative embodiments that resultfrom combining, integrating, and/or omitting features of theembodiment(s) are also within the scope of the disclosure. Wherenumerical ranges or limitations are expressly stated, such expressranges or limitations should be understood to include iterative rangesor limitations of like magnitude falling within the expressly statedranges or limitations (e.g., from about 1 to about 10 includes 2, 3, 4,etc.; greater than 0.10 includes 0.11, 0.12, 0.13, etc.). For example,whenever a numerical range with a lower limit, R_(I), and an upper,R_(u), is disclosed, any number falling within the range is specificallydisclosed. In particular, the following numbers within the range arespecifically disclosed: R=R_(I)+k*(R_(u)−R_(I)), wherein k is a variableranging from 1 percent to 100 percent with a 1 percent increment, i.e.,k is 1 percent, 2 percent, 3 percent, 4 percent, 5 percent, . . . , 50percent, 51 percent, 52 percent, . . . , 95 percent, 96 percent, 97percent, 98 percent, 99 percent, or 100 percent. Moreover, any numericalrange defined by two R numbers as defined in the above is alsospecifically disclosed. Use of the term “optionally” with respect to anyelement of a claim means that the element is required, or alternatively,the element is not required, both alternatives being within the scope ofthe claim. Use of broader terms such as comprises, includes, and havingshould be understood to provide support for narrow terms such asconsisting of, consisting essentially of, and comprised substantiallyof. Accordingly, the scope of protection is not limited by thedescription set out above but is defined by the claims that follow, thescope including all equivalents of the subject matter of the claims.Each and every claim is incorporated as further disclosure into thespecification and the claims are embodiment(s) of the present invention.

What is claimed is:
 1. A method of preparing a composite article comprising: providing a first bias assembly with a first bias roll; providing a first non-bias assembly with a first non-bias roll; positioning the first bias assembly to a dispensing position; dispensing a bias ply from the first bias roll along a bias path on a mold; cutting the bias ply; positioning the first non-bias assembly to a dispensing position; dispensing a non-bias ply from the first non-bias roll; and cutting the non-bias ply; wherein the bias path and the non-bias path are substantially parallel.
 2. The method according to claim 1, wherein the first bias assembly and the first non-bias assembly are disposed on a frame.
 3. The method according to claim 1, wherein the first bias assembly is disposed on a first frame and the first non-bias assembly is disposed on a second frame.
 4. The method according to claim 1, further comprising a step of cutting a reinforcement strip from at least one of the bias ply and the non-bias ply. 